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Suryauday Spinning Mills

Suryauday Spinning Mills

100% Synthetic Spun Yarn — Single & Multifold
Tamil Nadu
Systech Texora Spin Edition
Synthetic Spun YarnPSF/VSFSingle YarnMultifold YarnTFOConversion CostingTexora Spin
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The Challenge

Managing a 100% Synthetic Spinning Operation with Single and Multifold Yarn Lines

Suryauday Spinning Mills, a 38,000-spindle unit producing 100% synthetic spun yarn in both single and multifold variants, faced challenges unique to a PSF/VSF-based operation. Unlike cotton mills, their raw material management revolves around polyester staple fibre (PSF) and viscose staple fibre (VSF) lots — tracked by denier, cut length, lustre, and supplier. With both single yarn production and TFO (Two-for-One) multifold lines running in parallel, they needed a system that could handle PSF lot blending, track single yarn as both a finished product and an intermediate input to TFO, and compute layered conversion costing from fibre to multifold cone.

PSF/VSF lot management was manual — no tracking by denier, cut length, or supplier-wise quality
Lot blending for synthetic fibre had no optimization — different from cotton bale mixing
Single yarn tracked as finished goods but not as intermediate input to TFO multifold lines
Multifold costing was guesswork — no layered costing of single yarn cost + TFO conversion cost
Production data captured in registers — reports available only next day
Quality parameters for synthetic yarn (denier variation, tenacity, elongation) recorded manually
Waste tracking inconsistent — synthetic waste has different recovery economics than cotton waste
No real-time machine efficiency or downtime visibility across ring frames and TFO machines

The Solution

Systech Texora Spin — Built for Synthetic Spun Yarn Operations

Implemented Systech Texora Spin Edition tailored for a 100% synthetic spinning operation — covering PSF/VSF lot management, lot blending optimization, process-wise production tracking through to TFO multifold, layered conversion costing, and real-time dashboards across both single and multifold lines.

PSF/VSF lot management with denier, cut length, lustre, and supplier-wise tracking
Synthetic fibre lot blending optimization based on fibre properties and cost
Process-wise production tracking from blow room through carding, drawing, speed frame, and ring frame
Single yarn tracked as both finished product and intermediate input to TFO lines
TFO multifold production tracking with ply-wise details, twist parameters, and output counts
Layered conversion costing — single yarn cost + TFO conversion cost for accurate multifold pricing
Quality management for synthetic yarn parameters — denier variation, tenacity, elongation, and shrinkage
Synthetic waste management with process-wise collection and recovery economics
Real-time production dashboards across ring frames and TFO machines with shift reports
Implementation Timeline:10 weeks implementation including data migration and training

The Results

Measurable business impact

PSF Lot Tracking
Manual registersDenier & lot-wise digital tracking
Full traceability
Multifold Costing
ApproximateLayered conversion costing
Accurate pricing
Production Visibility
Next-day reportsReal-time across ring & TFO
Instant visibility
Costing Accuracy
No count-wise dataDaily count-wise P&L
Data-driven decisions
PSF/VSF lots tracked by denier, cut length, lustre, and supplier — full raw material traceability
Synthetic fibre lot blending optimized for cost and quality — a different challenge than cotton mixing
Single yarn flows seamlessly as intermediate input to TFO — no duplicate entries or tracking gaps
Layered multifold costing gives true cost of every multifold count including TFO conversion
Daily count-wise profitability for both single and multifold variants — management decides in real time
Synthetic waste tracked separately with its own recovery economics and accounting
Quality parameters specific to synthetic yarn monitored digitally with deviation alerts
Right-sized implementation for a 38K spindle mill — live in 10 weeks
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Most ERPs think spinning means cotton. Texora understood that our synthetic operation is fundamentally different — from PSF lot management to TFO conversion costing. The count-wise profitability across single and multifold lines has changed how we price and plan.

Management
Suryauday Spinning Mills

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